HUSABERG ENDURO FE 400 User manual

INDEX
1
1
2
3
4
5
6
7
8
9
11
10
12
SAFETY AND PRECAUTIONS Page 4-
GENERAL INFORMATION Page 6-
MAINTENANCE SCHEDULE Page 9-
CONTROLS Page 12-
WIRING DIAGRAMS Page 31-
INTRODUCTION Page 2-
STARTING PROCEDURE Page 15
ENGINE Page 16- A LUBRICATION SYSTEM
B IGNITION
C AIR FILTER
D VALVE ADJUSTMENT
WHEELS & BRAKES Page 23- A WHEELS
B CHAIN
C BRAKES
SUSPENSION Page 28- A SUSPENSION
B STEERING HEAD
C SWINGARM
FUEL & COOLING Page 20- A CARBURETTOR
B FUEL
C COOLING SYSTEM
CLUTCH & DECOMPRESSION Page 22

INTRODUCTION
2
11Please read and observe the following:
Warning
If the engine has to be running during any maintenance, make sure that the area is
properly ventilated. Never run the engine in a closed area though the exhaust fumes
are posionous and thus hazardous to your health and life.
Warning
Althoughthebatteryisofasealedconstruction, please takecare.Theelectrolytecontains
sulfuric acid and you must protect your eyes, skin and clothing if such fluid is assumed
to be leaking or likewise exposed. In case of contact, wash and flush thoroughly with
water and contact medical help if needed, especially if your eyes have been exposed to
the fluid.
Warning
Fuel is extremely flammable and explosive under certain conditions. Do not smoke or
expose the fuel to open fire or sparks.
SERVICE CONDITIONS:
1. Always use original Husaberg parts.
2. Use the special Husaberg tools when required.
3. Install new gaskets, o-rings, circlips etc whenever possible.
4. Always clean all parts thoroughly before assembly.
5. All screws, nuts and bolts etc. are in the metric system. Do not use incorrect tools.
Endurovägen, S-695 72 SWEDEN
www.husaberg.se
f[email protected]
PRINT & COPY RIGHTS
Thematerial andinformation includedinthisOwner’sManualare all ofthelatest editions
available at the time of the printing.
Husaberg Motor AB reserves the right to make changes regarding the products at any
time without prior notice.
This Owner’s Manual is subject to corrections without prior notice.
No part of this Owner’s Manual may be reproduced without written permission

INTRODUCTION
3
1
1
Always put the motorcycle on a stable centerstand
whenever removing either front or rear wheel.
ATTENTION:
Never ride your motorcycle under the influence of
alcohol,drugs,barbiturates or any other kind of medical
treatments hazardous to your riding performance.
ATTENTION:
Never ride in a too low or too high gear -
Neverlettheenginerunformorethanoneminutewhilestationary
It may cause severe mechanical damages
ATTENTION:
ATTENTION:
Service more frequently when
riding under hard conditions
ATTENTION:
Do not use a highpressure jet-cleaning
equipment on surfaces around
bearingsand other fragile components.
WARNING:
Do not check the coolant
level while the engine is hot.
ATTENTION:
Less clearances than the required
cause severe engine damages
Dear client,
We feel ourselves privileged and honoured to be the supplier of your choice of motorcycle.We
know for sure that our product will give you years of fun and performance though the Husabergs
are based upon decades of experience in racing and a dedication hard to find elsewere.You’re
bound to feel this through the inborn lively spirit of your bike.
Although mainly designed and constructed for competition purposes it is still very rider-friendly
but due to the design the product needs careful and proper maintenannce. In order to get the
most out of your "beast" and before any use of the motorbike; we highly recommend you to
carefully read this Owner's Manual through. We also recommend you to pay your outmost
attention to the following page regarding safety and precautions and always remember the
fundamental base of all activities on two wheels:
- "Do not overestimate your capabilities, follow the domestic regulations and do think about
your surroundings"
Although the Owner's Manual is put together and written in a way that will make it possible for
an average mechanical experienced person to take care of the maintenance, we recommend
you to let an authorized Husaberg dealer take care of at least the parts we’ve mentioned under:
Also, part of the maintenance has to be performed by an authorized dealer in order to fulfill the
terms of warranty.
If you follow the advice regarding the set-up and of course also regarding the vital maintenance
of the motorcycle; the Husaberg of yours will provide a maintained level of performance (read:
joy and satisfaction - the reason to your choice of brand).
The personnel of Husaberg Motor AB Sweden

SAFETY AND PRECAUTIONS
4
2
2
Never ride your motorcycle under the influence of
alcohol,drugs,barbiturates or any other kind of medical
treatments hazardous to your riding performance.
ATTENTION:
SAFETY
PROTECTION:
Always protect yourself with adequat clothing and protective apparel.
Always wear a helmet, goggles and boots.
MOTORCYCLE:
The motorcycle may become dangerous to ride if it is modified or if any other parts than
originalHusabergpartsareused.The use ofotherparts than originalmakesthewarranty
no longer valid.
Always keep your motorcycle in a safe state and in the best of conditions.
Regular cleaning and maintenance are extremely vital in order to avoid any mechanical
damages hazardous to you and/or your surroundings.
TRANSPORTATION:
Always transport your bike upright in order to avoid any leakages of oil and/or fuel.
Such fluids may increase the risk of fire. Always make sure that the bike is properly
fastened in a safe and firm position during transportation.
RIDING:
Always check the motorcycle for any deterioration/damages and any necessary
adjustments before you start the motorcycle (see "Pre-ride inspection").
Though the Husaberg motorcycle has a very high level of performance; always ride
with care and do not overestimate your capabilities. Get to know your Husaberg
motorcycle really well before you try to get the most out of it.
Never lend your motorcycle to any other rider unless you are sure that he/she is fully
capable of handling it.
Always obey all local and federal regulations and laws valid within the territory.
Never ride in terrain unfamiliar to you unless inspected and guaranteed by the local
authorities.
PRE-RIDE INSPECTION:
Make it a habit to give your motorcycle an inspection before and after every ride.
Always check all bolts and nuts and tighten if necessary - All for your own safety.
A clean and well lubricated bike makes for a safer ride as well as a higher value of the
machine. The Pre-ride Inspection Checklist on the next page is to be regarded as a
brief summary of the main important items to be controlled and, if necessary; to be
adjusted or replaced.

SAFETY AND PRECAUTIONS
5
2
2PRE-RIDE INSPECTION CHECK LIST
Engine oil Check the level and fill up if necessary.
Check for any leakages in the casing.
Ignition Check the sparkplug cap/HV lead for damages.
Radiator Check the coolant level and fill up if necessary.
Checkfor leakages and/ordamages of thecellsand hoses
and attachments.
Airfilter Clean, or if necessary, replace the filter
Carburettor Check the function of the throttle/cable and adjust/replace
any damaged parts if necessary.
Adjust the idling- and/or mixture screw if necessary.
Clutch Check the function and for any leakages.
Decompression Check the function of the manual and the semi-automatic
decompressionleverandadjustifnecessary (non-electrical
starter models only).
Chain Check and adjust/replace the chain if necessary.
Check the sprockets and replace if necessary.
Suspension Checktheoperationofthefrontforkandtheshockabsorber
and adjust if necessary.
Check and tighten the swingarm if necessary.
Wheels Check the air pressure of the tyres and fill up if necessary.
Check the spokes and tighten if necessary.
Brakes Check the level of brakefluid and fill up if necessary.
Check for any leakages and the function of the brakes.
Adjust levers and/or replace hoses/pads if necessary.
Fuel Check the level and fill up if necessary.
Check for any leakages in the fuel lines.
Steering Check the clearance of the steering head bearings and
adjust if necessary.
Controls Check the function of the speedometer or odometer (if
incl.in equipment).
Lighting Check the functions of the front-, tail-, and brake lights
(and any occuring turn signals).

GENERAL INFORMATION
6
3
3SPECIFICATIONS
ENDURO MOTOCROSS ELDURO DESERT (FX)
Liquid cooled, 4-stroke single cylinder, SOHC-4 valves
400-models:399cc / Bore 92,0 mm x Stroke 60,1 mm
501-models:501cc / Bore 95,0 mm x Stroke 70,7 mm
600-models:595cc / Bore 95,0 mm x Stroke 84,0 mm
400-models:12,0:1
501-models:11,8:1
600-models:11,6:1
One automatic system activated by the
camshaft, oneactivatedbythekickstarter
and one operated by a manual lever
Fully automatic system activated by
the camshaft plus one operated by a
manual lever
Kick starter Electrical- and kick starter
2 mm ± 1 mm 2 mm ± 1 mm
Intake and Exhaust:0,10 mm
SUBJECT/MODEL
Engine type
Displacements
Compression ratio
Decompression system
Start system
Decomp.cable clearance
Valve clearance Orbit oilpump and reedvalve controlled lubrication
Oil-cooled piston and connecting rod
Replaceable micro filter and washable oil screen
1,0 Litre Synthetic SAE 5W-50 API SG/CF (minimum SAE 15W-50)
SEM, CDI, DFC™;Dynamic Force Control
Lubrication
Engine oil
Ignition NGK DCPR8E / 0,7 mmSpark plug / gap 1,3 litre of 50% Anti-freeze, with corrosion inhibitor, and 50% waterCoolant 12V / 70 + 70 W Not available 12 V / 70 + 70W 12 V / 70 + 70 WAlternator
Inox steel pipes, 2 into 1 collector, Aluminium/Inox silencer (FCTitanium/Inox)
US-versions except FC models equipped with spark arrester
Exhaust system
Fuel capacity All models except FR 600 E:9 litres
FR 600 E: 25 litres
520 O-ring chain
15/42 - 2,800
15/42 - 2,800
13/48 - 3,692 13/48 - 3,692 13/48 - 3,692
15/48 - 3,200 (15/48 - 3,200) 15/48 - 3,200 15/48 - 3,200
15/48 - 3,200 (15/42 - 2,800) 15/48 - 3,200 15/48 - 3,200
400-models:Dellorto PHM 38
501- & 600-models:Dellorto PHM 40
Dual Sport USA - FS 600:Edelbrock Qwiksilver 38
All models except FR 600 E:Single foam filter
FR 600 E:Double foam filters
RON 98 (octane), unleaded
29/78 - 2,690
Spur gears
Clutch hydraulic oil
Secondary transmission
Ratios 501/4-speed
600/4-speed
400/6-speed
501/6-speed
600/6-speed
Carburettor
(std. jetting see page 8)
Air filtration
Fuel
Ratio
Primary transmission
Hydraulic, 7 friction- and 8 mating plates in oil bathClutch
Gearbox
Ratios 1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Mineral oil SAE 2-7W
6-speedWR 4 or (6)-speed CR 6-speedWR 6-speed S-WR
15/32 - 2,133 13/34 - 2,615 15/32 - 2,133
*17/30 - 1,765 18/28 - 1,555 17/30 - 1,765 18/28 - 1,555
*20/27 - 1,350 20/25 - 1,250 20/27 - 1,350 20/25 - 1,250
*23/24 - 1,043 23/24 - 1,043 23/24 - 1,043 23/24 - 1,043
25/22 - 0,880 (24/22 - 0,917) 25/22 - 0,880 25/22 - 0,880
*FC 4-speed WR
*13/34 - 2,615
(25/21 - 0,840) 27/20 - 0,741 27/20 - 0,741 27/20 - 0,741

GENERAL INFORMATION
7
3
3
SPECIFICATIONS
1490 mm
1490 mm
930 mm
900 mm
380 mm
350 mm
810 mm
810 mm
2200 mm
2150 mm
Wheelbase
Wheelbase Super M.
Seat height
Seatheight Super M.
Groundclearance
Groundclearance SuperM.
Overall width
Overall width Super M.
Overall length
Overall length Super M.
Weight (dry) kg:
400/6-speed
501/4-speed
501/6-speed
600/4-speed
600/6-speed
Super Motard + 2,5 kg
Front fork oil
Front fork oil capacity
Brake fluid
Lubrication of bearings
Wear limit brake pads
Wear limit clutch discs
Drive chain
Wear limit drive chain
12V 65/50 W - P43t
12V 45/40 W - BA20d
12V 21/5 W - BAY15d
12 V 4W - BA9s
12V 10 W - BA15s
12 V 2W - BA7s
Not applicable
Headlight
HeadlightUS-models
Tail- / Stop light
Parking light
Turn signal light
Speedometerlight
Battery
Main fuse
ENDURO ELDURO MOTOCROSS DESERT (FX)
Heat-treated (DIN) 25CrMo4 steel
SUBJECT/MODEL
Frame 28,5°Caster Hydraulic front fork ø 43 mm / 280 mm
WP MXMA 4358 HUSABERG-E
Progressive Damping System - PDS
WP 5018 HUSABERG-E 320 mm
Hydraulic front fork ø 43 mm / 280 mm
WP MXMA 4358 HUSABERG-MX
Progressive Damping System - PDS
WP 5018 HUSABERG-MX 320 mm
Front suspension
Rear suspension
BREMBO, hydraulic, twin piston (Super Motard four piston) floating caliper
ø 260 mm (Super Motard ø 320 mm) stainless steel brake disc
BREMBO, hydraulic, single piston floating caliper
ø 220 mm stainless steel brake disc
Front brake
Rear brake
Tyre pressure (cold)
Front
Front Super M.
Rear
Rear Super M.
Front rim/tyre
Front rim/tyre Super M.
Rear rim/tyre
Rear rim/tyre Super M.
Not applicable 12 V 8 Ah
15 A Not applicable 12 V 8 Ah 15 A
104,8
105,2
105,7
112,4
112,5
112,9
102,0
102,4
102,4
102,9
112,0
112,4
FR 600 E: 118,9
WP SAE 5
According to WP Manual
DOT 4
Molybdenum sulphide grease
1,5 mm
19,6 mm
D.I.D.O-ring
272 mm - 18 chain reels (tensioned, center distance between reels)
EXCEL1.60x21”/90/90-21”
EXCEL2.15x18”/130/80-18” 2.15x19”/130/70-19” 2.15x18”/130/80-18”
Not applicableBEHR3.50X17”/120/70-17”
Not applicableBEHR4.25x17”/160/60-17”
Offroad use: 0,8 bar (12,0 psi) / Street Use: 1,0 bar (14,5 psi)
Offroad use: 0,8 bar (12,0 psi) / Street Use: 1,0 bar (14,5 psi)
Not applicable2,2 bar (31,9 psi)
Not applicable2,0 bar (29,0 psi)

GENERAL INFORMATION
8
3
3
1. Flywheel puller - Article No. 270028-01
2. Flywheel holder - Article No. 270030-01
Tool kit - Article No. 390029-01
CARBURETTOR STD. JETTINGS
MODEL/SUBJECT
(Exploded view number)
Main
jet
# 6
Needle
jet
# 4
Needle
# 3
Needle
clippos.
# 26
Pilot
jet
# 7
Throttle
# 2
Float
valve
# 9
Mixture
screw
# 33
Start
jet
# 8
ENDURO FE 400 190 DR 270 K 35 #3 35 40 300
FE 501 190 DR 270 K 51 #3 33 40 300
FE 600 195 DR 270 K 35 #3 48 50 300
ENDURO ECE FE 400 110 DR 266 K 51 #2 48 70 300
FE 501 110 DR 264 K 35 #4 33 70 300
FE 600 110 DR 268 K 51 #3 42 70 300
ENDURO USA FE 400 190 DR 270 K 35 #3 35 40 300
FE 501 190 DR 270 K 35 #3 33 40 300
FE 600 195 DR 270 K 51 #3 33 40 300
ELDURO FE 400 E 190 DR 270 K 35 #3 35 40 300
FE 501 E 190 DR 270 K 51 #3 33 40 300
FE 600 E 195 DR 272 K 51 #3 48 50 300
ELDURO ECE FE 400 E 110 DR 266 K 51 #2 48 70 300
FE 501 E 110 DR 264 K 35 #4 33 70 300
FE 600 E 110 DR 268 K 51 #3 42 70 300
ELDURO USA FE 400 E 190 DR 270 K 35 #3 35 40 300
FE 501 E 190 DR 270 K 35 #3 33 40 300
FE 600 E 195 DR 270 K 51 #3 33 40 300
MOTOCROSS FC 501 190 DR 270 K 35 #3 33 40 300
FC 600 195 DR 272 K 51 #3 33 40 300
DESERT USA FX 501 E 190 DR 270 K 35 #3 33 40 300
FX 600 E 195 DR 270 K 51 #3 33 40 300
RALLYE FR 600 E 195 DR272 K 51 #3 48 50 300
RALLYE USA FR 600 E 195 DR 270 K 51 #3 33 40 300
DUAL SPORT FS 600 E - - K 6 19 out - - -
2 turns
1½turns
1½turns
1¼turns
1 turn
1½turns
2turns
1½turns
1½turns
2turns
1½turns
1½turns
1¼turns
1 turn
1½turns
2turns
1½turns
1½turns
1½turns
1½turns
1½turns
1½turns
1½turns
1½turns
-
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
-

GENERAL INFORMATION
9
3
3
4MAINTENANCE SCHEDULE
C: Clean - I: Inspect - R: Replace - *Maximum 12 months interval
Chassis - Enduro and Elduro models
Chassis - Motocross and Desert models
SRUOH/TCEJBUSSRUOH/TCEJBUS SRUOH/TCEJBUS SRUOH/TCEJBUSSRUOH/TCEJBUS
55
5
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*liokroftnorF RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR
*diulfekarB RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR
sgnihsub/sgniraebmragniwS II
I
II II
I
II II
I
II II
I
II
sgnihsubrebrosbakcohS II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
sgniraebdaehgnireetS II
I
II II
I
II II
I
II II
I
II
sgniraebleehW II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
SRUOH/TCEJBUSSRUOH/TCEJBUS SRUOH/TCEJBUS SRUOH/TCEJBUSSRUOH/TCEJBUS
010101010102020202020303030303040404040405050505050606060606070707070708080808080909090909001001 001 001001011011 011 011011021021 021 021021031031 031 031031041041 041 041041051051 051 051051061061 061 061061071071 071 071071081081 081 081081091091 091 091091002002 002 002002
*liokroftnorF RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR
*diulfekarB RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR
sgnihsub/sgniraebmragniwS II
I
II II
I
II II
I
II II
I
II
sgnihsubrebrosbakcohS II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
sgniraebdaehgnireetS II
I
II II
I
II II
I
II II
I
II
sgniraebleehW II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
TORQUE VALUES
5 NmOil filter cover screws 5 Nm Apply a threadlock liquidReed valve screws 5 NmValve inspection cover screws 5 Nm
Waterpump cover screws
SUBJECT TORQUE NOTE
5 NmIntake manifold screws
Standard torque values M8 M10
25 Nm 40 Nm M12 40 Nm M16 125 Nm
10 NmCrankcase screws 8 NmStator screws
10 Nm
Exhaust pipe screws 10 NmGearshift lever screw 10 Nm Apply a threadlock liquidKick start lever screw 10 NmTransmission cover screws 10 NmValve cover screws 12 Nm
Oil drain plug
10 Nm
Cylinder head (M6) screws
12 NmValve adjustment lock nuts 12 Nm
Spark plug
25 Nm Apply a threadlock liquidUpper timing sprocket screws 44 NmCylinderstud nuts 50 Nm Left-handthreadFlywheel nut 80 NmPrimary gear wheel nut
15 NmFront fork triple clamp screws (M8)
125 NmSwingarm shaft nuts M6
10 Nm
M5
8 Nm
M4
6 Nm

MAINTENANCE SCHEDULE
10
4
4
SRUOH/TCEJBUSSRUOH/TCEJBUS SRUOH/TCEJBUS SRUOH/TCEJBUSSRUOH/TCEJBUS
55
5
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RALUGERRALUGER RALUGER RALUGERRALUGER
lioenignE RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR
neercsliO CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC
retliforcimliO RR
R
RR RR
R
RR RR
R
RR RR
R
RR
evlavdeer.lcnipmupliO C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I
*diuqiltnalooC RR
R
RR
)pac.lcni(gulpkrapS II
I
II RR
R
RR II
I
II RR
R
RR
**noitingI/rotanretlA II
I
II II
I
II
ecnaraelcevlaV II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
sgnilaes&sediug.lcnisevlaV II
I
II
renoisnet.lcniniahcgnimiT II
I
II
nip&sgnir.lcninotsiP II
I
II
rednilyC II
I
II
dorgnitcennoC II
I
II
niptfahsknarC II
I
II
scsid.lcnimsinahcemhctulC II
I
II II
I
II
***rotterubraC C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I
pmupleufmgarhpaiD C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I
msinahcemtratskciK II
I
II
msinahcemtfihsraeG II
I
II
msinahcemleehweerF:LE II
I
II
SGNIRAEBSGNIRAEB SGNIRAEB SGNIRAEBSGNIRAEB
dorgnitcennoC RR
R
RR
tfahsknarC II
I
II
tfahsniamxobraeG II
I
II
tfahsyradnocesxobraeG II
I
II
murdtfihS II
I
II
tfahsmaC II
I
II
etalperusserphctulC II
I
II
msinahcemtratskciK II
I
II
leehwraegetaidemretnI II
I
II
tfahsetaidemretnI:LE II
I
II
recnalabretnuoC:LE II
I
II
SGNIHSUBSGNIHSUB SGNIHSUB SGNIHSUBSGNIHSUB
dorgnitcennoC RR
R
RR
smrarekcoR II
I
II
tfahstratskciK II
I
II
tfahshctulC II
I
II
Engine - Motocross and Desert models
Please observe: Riding under hard conditions demands more frequent maintenance
C: Clean - I: Inspect - R: Replace
* Maximum 12 months interval - ** Clean whenever the engine has been washed - *** I(R):Especially needle and needle jet